Handheld dimensioning system with measurement-conformance feedback

ABSTRACT

A system and method for obtaining a dimension measurement that conforms to a conformance criteria is disclosed. The dimensioning system provides either (i) feedback to confirm that the measurement complies with the criteria or (ii) information on how the measurement geometry could be adjusted in order to provide a compliant measurement in a subsequent dimension measurement.

FIELD OF THE INVENTION

The present invention relates to dimensioning systems, and inparticular, to a handheld dimensioning system that can provide feedbackrelating to a dimension measurement's conformance with ameasurement-accuracy criteria.

BACKGROUND

Dimensioning is the process of measuring the cubic space that an object(e.g., package) occupies. Automatic dimensioning systems may be used forcalculating an object's dimensional weight to facilitate storage,handling, transporting, and/or invoicing. Transport vehicles and storageunits, for example, have both volume and weight capacity limits. Theycan become full before they reach their weight capacity leading toinefficiencies. By dimensioning objects, parcels, and pallets, shippingcompanies and warehouses can make optimal use of space and charge forservices accordingly. As a result, dimensioning systems that help gatherthis information without causing a disruption in the workflow are highlydesirable. As these devices become increasingly part of commercialprocesses, their accuracy becomes an important characteristic tounderstand.

Standards have been developed for weights and measures. These standardspromote a healthy business and consumer climate by providingspecifications to insure uniform and equitable measurements. Measurementdevices that comply with these specifications are trusted and usefultools for commerce.

Handheld dimensioners may be used for automatically determining thedimensions of a package without manually manipulating the package. Themeasurement environments for this type of dimensioner are highly varied,and as a result the accuracy (i.e., the minimum dimension that can bemeasured) of the handheld dimensioner may vary for different measurementcircumstances. Industry standards require that dimension measurementsconform to an accuracy criteria, however it is easy for a typical userto violate these criteria when using a handheld dimensioner. Forexample, when a user tries to measure a small package at a largedistance then the accuracy of the measurement may violate thespecifications of the standard. Here, a more accurate measurement (i.e.,conforming to the standard) could be made if the handheld dimensioningsystem was moved closer and the measurement was repeated.

Therefore, a need exists for a handheld dimension system thatautomatically provides measurement-conformance feedback so the handhelddimensioning system's measurements remain in conformance.

SUMMARY

Accordingly, in one aspect, the present invention embraces a method forgenerating measurement-conformance feedback using a handhelddimensioning system. The method includes the step of using adimensioning-system image-sensor to capture at least one image an object(or objects) in the handheld dimensioning system's field-of-view. Adimensioning system processor then uses this image (or images) tocompute a measurement geometry. The processor uses the measurementgeometry to derive a measurement accuracy, and then identify at leastone conformance criteria based on this measurement accuracy. Thecaptured image is then used by the dimensioning-system processor toobtain a dimensioning measurement. By comparing the dimensionmeasurement to the conformance criteria, the dimensioning-systemprocessor may generate measurement-conformance feedback corresponding tothe results of this comparison.

In an exemplary embodiment, the method's measurement-conformancefeedback includes an adjustment message. The adjustment message providesinstructive prompts to facilitate the adjustment of the measurementgeometry in order to achieve measurement conformance.

In another aspect, the present invention embraces a handheld dimensionsystem that provides measurement conformance feedback. The dimensioningsystem includes an imaging subsystem. The imaging subsystem uses atleast one image sensor to capture an image of an object (or objects)within a field-of-view. The image sensor (or sensors) arecommunicatively coupled to a control subsystem. The control subsystemincludes a processor (or processors) and at one non-transitory storagemedium that can store information and processor-executable instructions.These processor-executable instructions configure the processor toreceive images from the image sensor (or sensors) and compute (usingthese received images) a measurement geometry. A measurement accuracycorresponding to the measurement geometry is then derived and aconformance criteria based on this measurement accuracy is identified.The processor-executable instructions next configure the processor touse the received images to obtain a dimension measurement. By comparingthe dimension measurement to the identified conformance criteria,measurement-conformance feedback is generated.

In an exemplary embodiment, the handheld dimensioning system'sconformance criteria is in compliance with the specifications fordimension measuring devices described in the 2013 edition of the NISTHandbook 44, section 5.58 and is hereby incorporated by reference.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts the measurement geometry.

FIG. 2 schematically depicts a block diagram of an exemplarydimensioning system.

FIG. 3 schematically depicts a flow chart of an exemplary method forgenerating measurement-conformance feedback.

DETAILED DESCRIPTION

The present invention embraces a handheld dimensioning system capable ofproviding measurement-conformance feedback regarding the accuracy of themeasurement.

Dimensioning is the process of remotely measuring an object's dimensionsusing a dimensioning system (i.e., dimensioner). Typically, the objectanalyzed is a cubic package and the dimension measured is the object'svolume. Measuring a package's volume is especially important in theshipping and warehousing industries, which may have space and/or weightrestrictions. For example, the cost to ship a package has historicallybeen based on the package's weight. Charging by weight alone, however,may cause a shipment of a lightweight package with a large volume tobecome unprofitable. As a result, dimension measurements are oftenrequired to compute shipping costs.

Dimensioning systems may be static in the sense that a package isunmoving during a measurement. Alternatively, a dimensioning system maybe dynamic where the package moves during measurement (e.g., movingalong a conveyor). In both of these cases, the dimensioning system istypically mounted in a fixed position and the imaging environment iscarefully controlled. The most promising dimensioning systemconfiguration, however, is handheld, which could adapt to almost anyenvironment.

Handheld dimensioning is a challenging problem. In handheldapplications, the environment is uncontrolled and the dimensioner mustaccommodate a range of measurement conditions, including lighting,motion, and the measurement geometry (e.g., spatial relationships andorientations). In addition, handheld applications typically have a lowtolerance for excessive measurement times or alignment complexities.Thus, the sensing technology chosen for such applications mustaccommodate these issues.

A variety of sensing technologies have been employed for dimensioning.One exemplary sensing technology uses a three-dimensional (i.e., 3D)camera to obtain depth information. 3D cameras use the displacement inthe apparent position of an object when viewed along two lines of sight(i.e., parallax) to derive depth information.

Another exemplary sensing technology uses structured light. Structurelight is the process of projecting a known light pattern (e.g., dots,grids, bars, stripes, checkerboard, etc.) onto a scene (i.e., field ofview). A pattern image is then captured by an image sensor anddistortions in the pattern caused by objects in the field-of-view can beanalyzed to derive depth information.

Yet another exemplary sensing technology uses time-of-flight (TOF) todetermine depth information. Here the depth information can be derivedby calculating the time it takes for a projected light beam to reflectfrom an object back to a sensor (i.e., time-of-flight). Time-of-flightis similar to the principles of radar, except that a light pulse is usedinstead of an RF pulse.

In each of these exemplary embodiments, an imaging subsystem with atleast one image sensor is used to capture an image (or images) of anobject (or objects) in a field-of-view. A dimensioner can also measurethe space that is not occupied by objects. For example, the volume leftin a delivery truck, the dimensions of an empty concrete form, or thevolume between attic beams. In each of these examples, a volumecalculation would be helpful to insure proper filling.

Importantly, the accuracy for dimensioners depends on the measurementgeometry and the sensor-subsystem specification (e.g., resolution,field-of-view, etc.). This accuracy may change depending on themeasurement conditions (e.g., the measurement geometry).

Measurement geometry refers to the dimensioning-measurement setup (e.g.,the spatial relationship between the dimensioning system and theobject). As shown in FIG. 1, a dimensioning system's 2 field-of-view 3is placed in front of an object for dimensioning 1. The object is at arange 4 (i.e., the distance between the dimensioning system and theobject) so that it is completely encompassed within the field-of-view 3.Typically, three sides must be visible to the dimensioning system 2 forvolume measurements. This means that the edges 5,6 of an object surface9 should create an angle 7 with respect to the dimensioning system asshown in FIG. 1. In other words, an object surface 9 must be visible tothe imaging subsystem for sensing. For example, when using a projectedlight pattern to sense depth information (e.g., structured light), anobject's side must reflect some minimum fraction of the light pattern inorder for depth information for that surface to be derived. In theexemplary case shown in FIG. 1, the object 1 can be rotated 8 to adjustthis angle 7. A possible embodiment of the present invention is toprovide feedback to facilitate the adjustment (e.g., rotation, range,etc.) of the measurement geometry in order to make sensing possible. Inother words, the dimensioner may recognize poorly positioned objects andprovide prompts alerting a user and offering adjustment messages to makedimensioning possible (and/or more accurate).

Dimensioning-measurement confidence may be based on calculations usingthe received image. These calculations generate a confidence level forthe dimensioning measurement. Specifically, calculating dimensions onepixel to either side of an object edge provides the range of confidencefor the dimensioning measurement. For example, when the side surface 9of the object 1 is viewed obliquely (as shown in FIG. 1), a single pixelconsumes a larger portion of the image plane. Thus, calculating thesurface dimensions one pixel to either side of an edge will show avariation in dimension measurements that is large with respect to thedimensions of the side 9. Conversely, if a box side is viewed nearlystraight on, then calculating surface dimensions one pixel to eitherside of an edge will show only a small variation with respect to thedimension of that side. As a result, there is a higher confidence levelassociated with a dimensioning measurement for a side viewed nearlystraight on than for one viewed obliquely.

The range 4 is important for dimension measurement accuracy. In general,the closer the object is to the dimensioning system, the greater theaccuracy of the measurement. Put another way, the increment ofmeasurement is smaller for closer objects than for objects further away.This can be understood by considering the field-of-view's size withrespect to the object. If the dimensioning system, for example, samplesdepth evenly over the field-of-view 3, then small, faraway objects thatoccupy a small fraction of the field of view will have reduced depthsampling and therefore may be measured with less accuracy.

Guidelines for dimensioning measurements are provided for the UnitedStates by the National Institute of Standards and Technology (NIST) inthe “NIST Handbook 44” 2013 edition and is therefore hereby incorporatedby reference. These guidelines state that for a measurement to conformto the standard, the minimum object dimension must be at least twelve(12) times the smallest increment of length that can be measured.

To help understand the NIST guidelines consider the following exemplarydimensioning scenario. Two boxes at a distance of twelve feet (12′) areto be measured using a dimensioning system. One box (i.e., box-one) is acube of thirty-nine inches (39″) per side and the other box (i.e.,box-two) is a cube of thirteen inches (13″) per side. Based on the rangeand the details of the imaging subsystem, suppose that the smallestincrement of length that the exemplary dimensioning system can measureat this range (i.e., the increment of measurement) is 2 inches (2″).Box-one may be measured accurately and a typical measurement might bethirty-eight (38″) or forty (40″). Box-two may return a measurement(e.g., 12″ or 14″) but this measurement would not be in conformance withthe standard for accuracy since box-two is only thirteen inches (13″)per side and the minimum length that can be measured (and still be inconformance with the standard) must be twelve times the smallestincrement (i.e., 12×2″=24″).

Now suppose that the measurement geometry in this exemplary dimensioningscenario is changed so box-two is only three feet (3′) away from thedimensioning system. At this range the smallest increment of length thatcan be measured for this system is one-half an inch (0.5″). Box-one maynow be measured in conformance with the standard and a typicalmeasurement might be thirteen inches (13″).

This example shows that while a measurement may be returned from adimensioning system for all reasonable measurement geometries, themeasurement returned may not be in conformance with the standard. Thismay not always be obvious to a user. What is needed is a dimensioningsystem that monitors this relationship between measurement accuracy andstandard and that can provide a user with feedback messages concerningmeasurement-conformance. Further, if a measurement is impossible thenthis same system may also notify the user of this.

It should be noted that while particular sensor technologies andstandards have been discussed so far, the concept disclosed could beapplied any dimensioning system that uses a camera and could be appliedusing any reference or standard as a basis of conformance. Further,while handheld dimensioning systems are the most obvious type ofdimensioning system that could utilize the measurement-conformancefeedback, any dimensioning system that has an adjustable measurementgeometry could make use of this as well.

A block diagram of an exemplary embodiment of a dimensioning system isshown in FIG. 2. A handheld dimensioner 2 is positioned so that anobject 1 may have its dimensions (e.g., volume) measured optically. Toaccomplish this measurement, the dimensioner 2 utilizes a variety ofsubsystems.

An imaging subsystem 10 captures depth information of the object 1 in afield of view 3. To accomplish this, the imaging subsystem uses animaging lens 11 to focus a real image of the field of view onto an imagesensor 12 to convert the optical image into an electronic signal. Theimage sensor 12 may be a charge coupled device (i.e., CCD) or a sensorusing complementary metal oxide semiconductor (i.e., CMOS) technology.The image sensor 12 typically includes a plurality of pixels that samplethe real image and convert the real-image intensity into an electronicsignal. A processor (e.g., digital signal processor (DSP)) 13 istypically included to facilitate the formation of the digital image.

The creation of depth information is facilitated with a second elementin the imaging subsystem that either transmits an optical signal (i.e.,projector) or images a scene (i.e., sensor). The lens 14 for the sensor(or projector) 15 is typically configured into a stereo arrangement withthe imaging lens 11 to allow for the collection of depth information(e.g., measurement of distances) using the principle of parallax. Thesensor (or projector) 15 is typically communicatively coupled to the DSP13 which facilitates is control, function, and communication.

A control subsystem 20 is communicatively coupled to the DSP 13 used bythe sensor (or projector) 15 and the image sensor 12. The controlsubsystem 20 includes one or more processors 21 (e.g., one or morecontrollers, digital signal processor (DSP), application specificintegrated circuit (ASIC), programmable gate array (PGA), and/orprogrammable logic controller (PLC)) to configure the imaging subsystemfor the dimensioning data collection and then perform the processingnecessary on data collected to generate dimensioning measurements andfeedback. The processor 21 is typically configured byprocessor-executable instructions (i.e., a software program) stored inat least one non-transitory storage medium (i.e., memory) 22 (e.g., readonly memory (ROM), flash memory, and/or a hard-drive). Theprocessor-executable instructions, when executed by the processor 21configures the processor to: (i) receive images from the imagesensor(s), (ii) compute a measurement geometry, (iii) derive ameasurement accuracy, (iv) identify a conformance criteria, (v) obtain adimension measurement, and (vi) compare the dimension measurement to theconformance criteria in order to generate measurement-conformancefeedback.

The dimensioning system 2 may also include a user-interface subsystem 30to display dimension measurements (e.g., linear dimension or volume) andmeasurement-conformance feedback. In some embodiments, theuser-interface subsystem 30 may also facilitate the selection ofdimensioning surfaces for dimensioning.

The dimensioner 2 may also include a communication subsystem 40 fortransmitting and receiving information to/from a separate computingdevice or storage device. This communication subsystem may be wired orwireless and may enable communication with a variety of protocols (e.g.,IEEE 802.11, including WI-FI®), BLUETOOTH®), CDMA, TDMA, or GSM).

The subsystems in the dimensioner 2 are electrically connected via acouplers (e.g., wires or fibers), buses, and control lines to form aninterconnection subsystem 50. The interconnection system 50 may includepower buses or lines, data buses, instruction buses, address buses,etc., which allow operation of the subsystems and interaction therebetween.

A block diagram representing an exemplary method to generatemeasurement-conformance feedback for a dimension measurement is shown inFIG. 3. The method begins with the step of capturing of an image using adimensioning system 60. The image may contain one or more objects fordimensioning and covers a field of view. From this image, a measurementgeometry may be computed 61. The measurement geometry includesinformation such as, range, object-surfaces, and object-orientation.From this information, the measurement accuracy may be computed 62. Theaccuracy includes the smallest increment of length that can be measured.This accuracy can be used to identify the conformance criteria 63. Thisis the criteria stipulated by a standard (e.g., NIST Standard) or otherreference to assure the accuracy of a measurement. Next the image (orimages) captured can be used to compute a dimension measurement 64. Thedimension measurement may include object volume or a linear dimensionlike the length of an object surface. The dimension measurement may alsoinclude measurements of multiple objects within the field of view. Atthis point, the dimension measurement is compared to the conformancecriteria and a decision is made 65. If the dimension measurementcomplies with the conformance criteria, then a conformance message maybe generated 70 along with the dimensioning results 71. If, on the otherhand, the dimension measurement is found not to comply with theconformance criteria then a non-conformance message may be generated 80.Then, to facilitate a good measurement, a necessary adjustment for thedimensioning system (relative to the object) may be computed 81 (e.g.,move closer/farther-away or move left/right). If no solution is found,then an error message may be generated 82. This error may arise fordimensioning scenarios such as: objects with dimensions outside therange of the dimensioning system, measurement geometries beyond thedimensioner's capabilities (i.e., too far), or poor lighting. If asolution is found, however, an adjustment message may be generated 83 tohelp a user adjust the measurement geometry 84.

Once the dimensioning system is configured with a new measurementgeometry, then the process 60,61,62,63,64 may repeat and the newdimensioning results can be compared with the computed conformancecriteria for the new measurement geometry. The entire process continuesuntil a conforming dimensioning result is found or found to beunobtainable. Several iterations may be required to reach a conformingmeasurement, but in the end, the user is assured that the measurementcalculated is accurate and conforms to the standard.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

1. A method for generating measurement-conformance feedback using ahandheld dimensioning system, the method comprising: capturing by adimensioning-system image-sensor at least one image of at least oneobject in a handheld dimensioning-system field-of-view; computing by adimensioning-system processor using the at least one image a measurementgeometry; deriving by a dimensioning-system processor a measurementaccuracy corresponding to the measurement geometry; identifying by adimensioning-system processor at least one conformance criteria based onthe measurement accuracy; obtaining by a dimensioning-system processorusing the at least one image a dimension measurement; comparing by adimensioning-system processor the dimension measurement to theconformance criteria; and generating by a dimensioning-system processormeasurement-conformance feedback corresponding to the results ofcomparing the dimension measurement to the conformance criteria.
 2. Themethod according to claim 1, wherein the captured image comprises astructured light pattern.
 3. The method according to claim 1, whereinthe measurement geometry comprises a distance between the at least oneobject and the handheld dimensioning system.
 4. The method according toclaim 1, wherein the measurement geometry comprises an angle formedbetween the handheld dimensioning system and two points on an object inthe field-of-view.
 5. The method according to claim 1, wherein the atleast one conformance criteria corresponds to a multiple of themeasurement accuracy.
 6. The method according to claim 1, wherein thedimension measurement is a volume.
 7. The method according to claim 1,wherein the dimension measurement comprises a length.
 8. The methodaccording to claim 1, wherein the dimension measurement comprises asurface area.
 9. The method according to claim 1, wherein the dimensionmeasurement comprises a plurality of dimension measurements.
 10. Themethod according to claim 1, wherein the measurement-conformancefeedback comprises a conformance message.
 11. The method according toclaim 1, wherein the measurement-conformance feedback comprises anon-conformance message.
 12. The method according to claim 1, whereinthe measurement-conformance feedback comprises an error message.
 13. Themethod according to claim 1, wherein the measurement-conformancefeedback comprises an adjustment message, wherein the adjustment messagecomprises instructive prompts to facilitate the adjustment of themeasurement geometry in order to achieve measurement conformance. 14.The method according to claim 13, comprising after the measurementgeometry is adjusted, repeating the steps of capturing, computing,deriving, identifying, obtaining, comparing, and generating.
 15. Themethod according to claim 1, wherein the measurement-conformancefeedback comprises a dimension measurement and a conformance message,the conformance message indicating whether the dimension measurementconforms or does not conform to the conformance criteria.
 16. The methodaccording to claim 1, wherein the measurement-conformance feedbackcomprises an error message, the error message indicating that adimension measurement is unobtainable.
 17. A handheld dimensioningsystem providing measurement-conformance feedback, the dimensioningsystem comprising: an imaging subsystem comprising at least one imagesensor for capturing an image of at least one object within afield-of-view; and a control subsystem communicatively coupled to the atleast one image sensor, the control subsystem comprising at least oneprocessor and at least one non-transitory storage medium for storinginformation and processor-executable instructions, wherein theprocessor-executable instructions configure the processor to: (i)receive images from the at least one image sensor, (ii) compute usingthe received images a measurement geometry, (iii) derive a measurementaccuracy corresponding to the measurement geometry, (iv) identify aconformance criteria based on the measurement accuracy, (v) obtain usingthe received images a dimension measurement, and (vi) compare thedimension measurement to the conformance criteria in order to generatemeasurement-conformance feedback.
 18. The handheld dimensioning systemaccording to claim 17, wherein the handheld dimensioning systemcomprises a projector subsystem for projecting a light pattern onto theat least one object within the field-of-view, the projector subsystemlaterally offset from the imaging subsystem and sharing the samefield-of-view.
 19. The handheld dimensioning system according to claim17 wherein the handheld dimensioning system comprises two imagingsubsystems for capturing images of at least one object as view along twodifferent lines of sight, the imaging subsystems laterally offset fromeach other and sharing the same field-of-view.
 20. The handhelddimensioning system according to claim 17, wherein the measurementgeometry comprises the range between the imaging subsystem and an objectwithin the field of view.
 21. The handheld dimensioning system accordingto claim 17, wherein the measurement geometry comprises detected objectsurfaces.
 22. The handheld dimensioning system according to claim 21,wherein the measurement geometry comprises the number of object surfacesthat the imaging subsystem can resolve.
 23. The handheld dimensioningsystem according to claim 22, wherein the measurement-conformancefeedback indicates that an object is unmeasurable when less than threesurfaces can be resolved.
 24. The handheld dimensioning system accordingto claim 17, wherein the measurement accuracy is inversely proportionalto the range between the imaging subsystem and an object within thefield of view.
 25. The handheld dimensioning system according to claim17, wherein the conformance criteria is proportional to the computedaccuracy.
 26. The handheld dimensioning system according to claim 17,wherein the conformance criteria is in compliance with thespecifications for dimension measuring devices described in the 2013edition of the NIST Handbook 44, section 5.58.
 27. The handhelddimensioning system according to claim 26, wherein the conformancecriteria is twelve times the computed accuracy.
 28. The handhelddimensioning system according to claim 17, wherein themeasurement-conformance feedback indicates that the dimensionmeasurement is in conformance with a measurement-accuracy criteria whenthe dimension measurement is above the conformance criteria.
 29. Thehandheld dimensioning system according to claim 17, wherein themeasurement-conformance feedback comprises a certified measurement. 30.The handheld dimensioning system according to claim 17, wherein themeasurement-conformance feedback comprises advice for adjusting thehandheld dimensioning system with respect to the at least one object.31. The handheld dimensioning system according to claim 17, wherein thedimension measurement comprises incremental distances to an object andthe angles of the various surfaces.
 32. The handheld dimensioning systemaccording to claim 17, wherein the dimension measurement comprises thedimension measurements of a plurality of objects and themeasurement-conformance feedback comprises feedback for each object.